ACE&EASTMAN Instagraphic 204 Parts & Instructions 204A Manual English 040819 User

User Manual: ACE&EASTMAN Instagraphic 204 Parts & Instructions

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MODEL 204.1

MNL90008

08/31/05 Rev. G

Operation and Maintenance Manual

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY

- 3 -

Congratulations!

Your selection of the Insta Graphic Systems (IGS)

heat seal machine is a sound business decision.

IGS equipment is the result of the highest quality

engineering and time-tested design. Your new

machine combined with IGS's reputation of

innovation in the heat-sealing field, insures the

continuing capability of delivering the best

decorated substrates possible.

This manual describes installation, operation, and

maintenance procedures for your new model

machine, as well as easy to use instructions for

on-the-spot maintenance.

Your machine will have a long trouble-free life.

Read this manual. Keep it with your machine; it's

your key to proper operation and lasting service.

Installation

DOMESTIC

Use a separate 15 amp AC circuit.

Only industrial extension cords with

proper wire size should be used: size

16/3 wire for distances up to 25 feet,

and size 14/3 for distances up to 50

feet.

INTERNATIONAL

Use a designated 16 amp AC cir-

cuit. Only industrial extension

cords with proper wire size (2.5 sq.

mm) shall be used.

Limited Machine Warranty

Insta Graphic Systems (IGS) warrants this heat

seal machine, when operated under normal con-

ditions, to be free from manufacturing defects in

material and workmanship for a period of one

year on parts (lifetime on the upper heating

element) and 90 days on labor from the invoice

date.

This warranty will be effective only when IGS

authorizes the original purchaser to return the

product to the factory in Cerritos, California

freight prepaid, and only when the product upon

examination has proven to be defective.

This warranty does not apply to any machine

that has been subjected to misuse, negligence or

accident.

IGS shall not be liable for the injury, loss or dam-

age, direct or consequential, arising out of the use

or the inability to use the product.

No claim of any kind shall be greater in amount

than the sale price of the product or part to

which claim is made.

This is the sole warranty given by the company, it is

in lieu of any other warranties, expressed or implied,

in law or in fact, including the warranties of

merchantability and fitness for a particular use, and

is accepted as such by the purchaser in taking delivery

of this product.

Specifications

Voltage 115/120 Volts AC 50/60 Hertz

Model 204 14.6 Amps 1750 Watts

Voltage 230/240 Volts AC 50/60 Hertz

Model 204 9.6 Amps 2200 Watts

Weight Model 204 94 Pounds (42.7 KG)

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY

- 4 -

Operation

1. It is recommended that you review the "How

to Apply Instructions" (on our Product

Information Sheet) before beginning heat

sealing operations.

2. Turn the power on by pressing the POWER

button on the controller.

3. Set desired temperature and time then swing

the upper platen arm to its fully open

position, away from lower platen.

4. Allow the machine to warm up until the

selected temperature is reached.

5. Set the desired pressure by adjusting the

pressure adjust handle on the top of the

machine. To increase pressure, rotate handle

counterclockwise.

6. Place the substrate on lower platen,

smoothing out all wrinkles.

7. Position transfer or lettering on substrate.

8. Swing the upper arm into position directly

over the lower platen.

9. Close machine by pulling handle down into

locked position.

10. The timer will start automatically and a

buzzer will beep at the end of the time cycle.

11. Lift safety lock and pull handle up slowly and

move upper platen handle to its full open

position. This technique will avoid transfer

paper (cover) from being pulled off

prematurely due to suction from the

separating platens.

NOTE

For safety purposes, it is necessary to

push the handle into the locked position

after it is lifted. This will eliminate the

accidental lowering of the heat platen

handle.

12. Swing away arm to the extreme right hand

position and remove substrate.

Operation Timer/Temperature Control

Solid State Controller

This controller has three (3) control features:

1. Temperature - Temperature may be set from

225-450°F (107-232°C).

2. Time - Time may be set from 1 second to 10

minutes.

3. Counter - Cycle counter counts the number

of applications from 1 to 9999 (see

additional Notes - Counter).

Controller Operation

1. If the temperature is not being displayed,

press the MODE button until temperature is

displayed.

2. Push and hold SET button and

simultaneously push UP (↑) or DOWN (↓)

arrow buttons to the desired temperature

setting.

3. Press the MODE button until time is

displayed.

4. Push and hold SET button and

simultaneously push UP (↑) or DOWN (↓)

arrow buttons to the desired timer setting.

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY

- 5 -

ADDITIONAL NOTES:

Temperature

NOTE

Fahrenheit/Centigrade (Celsius)

Conversion

The temperature controller can be

programmed to display either °F or °C.

To change:

Press the MODE button until the

temperature is displayed, then push and

hold the SET button for 10 seconds.

Timer

• The controller has a count down timer that

automatically activates a buzzer at the

completion of the application.

• Timer display is minutes:seconds. Range is

00:00 to 10:00, Colons (:) flash while timer is

running.

NOTE

The timer or buzzer may be stopped

while the handle is in the down

position by pressing both the DOWN

(

↓

) arrow button and the UP (

↑

) arrow

button simultaneously. The timer will

automatically reset after the handle is

raised.

Counter

The controller has a built in cycle counter.

• Press MODE button until the counter is

displayed.

• Counter display range is 0000 to 9999.

• To reset the cycle counter, display the counter

reading, then push and hold both UP (↑) and

DOWN (↓) arrow buttons for 3 seconds until

the counter resets to zero (0000) on the

display.

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY

- 6 -

Safety Summary

WARNING

In case of power cord damage, do

not attempt to repair or replace the

power cord. Contact the manufac-

turer or the local distributor.

WARNING

Avoid touching hot surfaces while

operating the machine.

CAUTION

During normal operation, the base

of the machine needs to be installed

or placed above the wall socket.

CAUTION

When servicing or cleaning the

machine, make sure that the power

cord is removed from the wall

socket.

International Symbols

O

Power Off

I

Power On

Hot Surface

Risk of Electrical Shock

Protective Earth Terminal

Ground

Caution - Warning

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY

- 7 -

Preventive Maintenance Suggestions

The IGS heat seal machines are relatively

maintenance free. For long trouble-free life, the

following preventive maintenance should be

followed:

1. Do not heat seal items such as buttons, pins,

snaps, or zippers that tend to cut the silicone

rubber pad or scratch the Teflon heat platen.

2. Periodically clean the Teflon-coated heat

platen with a non-abrasive piece of cloth.

Stubborn stains may be cleaned, when

platen is cool, with mineral spirits.

3. When the heat platen is hot and not in use,

keep in open position (away from the silicone

rubber pad).

4. To prevent soiling of substrate, periodic

wiping of the entire exterior machine,

including platens, with a clean rag is

recommended. If necessary, use mineral

spirits for cleaning a cold machine. Since

mineral spirits are flammable, use precautions

and keep away from sparks, flame, or hot heat

platen.

5. This machine requires periodic lubrication

with a high-temperature, non-melting grease

(MPPL023).

A. Lubricate the post, handle and cam

assembly depending upon usage.

(Once every month if used

continuously.)

B. There are four (4) points of

lubrication:

a) Post

b) Lower Cam

c) Guide Post

d) Upper Pin Area

In addition, occasionally apply a few drops of

heavy machine oil to the upper portion of the

cam assembly. To lubricate the pressure

adjustment, raise cover put some high-

temperature grease MPPL023 grease on the

treaded section of the adjustment screw.

NOTE

Wipe off any excess oil or grease.

Replace cover, screw, and knob.

General Maintenance

It is recommended that you have the following

items available:

A. Regular screw driver

B. Phillips head screw driver

C. Small adjustable wrench

D. Needle nose pliers with insulated

handle

E. Set of Allen wrenches

F. Grease gun

G. Special high temperature grease

(MPPL023)

With the above items you should be able to

accomplish most repairs.

WARNING

Power cord replacement should be from

the manufacturer only (because it

requires a specially prepared cord).

Replacement of Silicone Rubber Pads

1. Make sure heat platen is cool.

2. Use tube of MPPC006 adhesive to bond

silicone rubber pad to metal platen.

NOTE: Read instructions on the tube package.

3. Be sure that the surface of the silicone platen

is clean. Use a mild solvent such as

mineral spirits.

4. The pad and metal must be thoroughly dry

and clean, before starting the bonding

operation.

5. Apply adhesive sealant to the metal platen.

Spread a thin even coat and apply pad

immediately. Apply pressure and position

pad making sure that there is no air

entrapment.

NOTE: A serrated blade such as used for laying down

rubber floor tiles would be helpful.

6. Allow to cure overnight under low pressure at

normal room temperature.

HEAT PLATEN

TEMPERATURE

CONTROL

RELAY

BLUE

12 Vac

INPUT

OP-1

SENSOR

OP-2

N/C

TIMER

START

CNO

MICRO

SW\ITCH

7

3

5

6

4

2

1

+12V

GN/YEL

BROWN

RED

GRAY

YELLOW

WHITE

PURPLE

WHITE

COIL

NO

C

12 Vac

5

2

6

8

7

11

12

1

TRANSFORMER

WHITE WHITE

GN/YEL

TRANSFORMER

BLUE

12 Vac

230 Vac

5

2

6

8

7

11

12

1

BROWN

BLUE

BROWN

GREEN/YELLOW

TERMINAL

BLOCK

204.1 Wiring Diagram - 10/08/04

WHITE

(BLUE-EUROPE)

BLACK

(BROWN-EUROPE)

RTD

BLACK

TAN

GREEN

(GN/YEL-EUROPE)

TAN

GN/YEL

1

2

GND

GREEN

BLACK

MODEL MODEL

204.1 204.1

NO DESCRIPTION 120V AC 230V AC

1 SHROUD, HEAT MPSS228 MPSS228

2 SCREW, PAN HD #10 X 1.00" LG MPSS143 MPSS143

3 INSULATION, FIBERGLASS 15X20 MPSP254 MPSP254

4 SCREW, SOCKET HD 1/4-20 X 4 LG MHSSH14204 MHSSH14204

5TUBING, SHRINK TFE AWG7 MPPS131 MPPS131

6 INSULATORS, SPACER (4/SET) MPSI089 MPSI089

7PLUG, BUTTON 7/8 IN MHPB78 MHPB78

8 SENSOR, TEMP. REPLACEMENT KIT MPPS210 MPPS210

9 POST, GUIDE MPSP084 MPSP084

11 PIN, PIVOT PLATEN MPP0139 MPP0139

13 CLEVIS, UPPER PLATEN MPSP221 MPSP221

14 PAD, SILICONE 15 X 20 BLK MPPP031 MPPP031

15 SCREW, PAN 10-24 X .50 LG MHSP102412 MHSP102412

16 HOUSING, INSTRUMENT MPSH015 MPSH015

17 WIRE, HEATER 14GA TGGT MPPW700 MPPW700

18 LABEL, CONTROLLER OVERLAY MPSL128 MPSL128

19 BOLT, HEX 5/16-18 X 1 LG STAINLESS MHBH516181S MHBH516181S

20 SCREW, BUT HD 1/4-20 X .75" LG MHSB142034 MHSB142034

21 HANDLE, PREASURE ADJUST F/204 MPSP014 MPSP014

22 SCREW, PAN HD 6-32 x 0.25 IN MHSP63214 MHSP63214

23 CONTROLLER, DIGITAL W/SWITCH MPC90003 MPC90003

25 HANDLE, SWINGAWAY 218A 228A MPH90002 MPH90002

26 WASHER, SAE 1/4" MHWSAE14 MHWSAE14

27 SWITCH, MICRO MPPS043 MPPS043

29 NUT, HEX 3/8-16 LOCKING MHNH3816 MHNH3816

30 PLUNGER SPRING DETENT 500 MPSP134 MPSP134

32 SCREW, SKT. HD 1/4-20 X.625 HD MHSSH142058 MHSSH142058

33 KNOB, HANDLE (MUSHROOM) MPPK017 MPPK017

34 CAP, VINYL BLK 5/16X.281 LG MPC90006 MPC90006

35 RELAY MPPR200 MPPR200

36 SCREW, BTN HD 1/4-20 X .875LG MHSB142078 MHSB142078

37 BLOCK, TERMINAL MH11096914 MH11096914

38 CLAMP, CABLE 5/16 IN. MHCC516 MHCC516

39 TRANSFORMER MPPT700 MPPT700

40 SCREW, RD HD 4-40X.625" LG MHSR44058 MHSR44058

41 SCREW, PRESSURE ADJUSTMENT MPSS070 MPSS070

42 POST, ARM ASSY MPSP204 MPSP204

43 PLATE, POST STOP MPSP20450 MPSP20450

45 WASHER, SAE 1/2" MHWSAE12 MHWSAE12

47 NUT, JAM SELF LOCKING 1/2-20 MHNHJSL1220 MHNHJSL1220

48 CLIPS, "E" MPSC240 MPSC240

49 PIN, CAM PIVOT (UPPER) MPSP262 MPSP262

50 SCREW, PAN HD 8-32 X .375" LG MHSP83238 MHSP83238

52 SAFETY LOCK MPSL241 MPSL241

53 WASHER, #8 SAE MHWSAE8 MHWSAE8

54 FITTING, GREASE (SHORT) MPSF145 MPSF145

55 PIN, ROLL (SAFETY LOCK) MPSR141 MPSR141

57 CAM MPSC220 MPSC220

58 SCREW, BUTTON HD 5/16-18 X1 LG MHSB516181 MHSB516181

59 NUT, HEX JAM 5/16-18 MHNHJ51618 MHNHJ51618

60 RING, "O" POST MPSS273 MPSS273

63 FEET,RUBBER (6/SET) MPF90004 MPF90004

68 BRACKET, POWER CORD MPSS163 MPSS163

69 STRAIN RELIEF 14/3 MPSS168 MPSS168

70 SCREW, PAN HD 10-24 X .375 LG MHSP102438 MHSP102438

71 CORD, POWER (USA) MPPW141 MPPW142

71A CORD, POWER (EUROPEAN) 230V N/A MPPW202

71B CORD, POWER (U.K) 240V N/A MPPW203

72 WIRE, HARNESS MPW90011 MPW90011

76 SPRING, CAM MPSS201 MPSS201

78 INSULATION, MICRO SWITCH MH700214 MH700214

79 WASHER, CUT 5/16" MHWC516 MHWC516

80 SCREW, SKT HD 5/16-18 X .50 LG MHSSH5161812 MHSSH5161812

82 CLAMP, CABLE 3/8" (STEEL) MH8863T2 MH8863T2

84 SCREW, PAN HD 8-32 X 1/4 LG MHSP83214 MHSP83214

87 SCREW, PAN HD 8-32 X 1/2 LG MHSP83212 MHSP83212

88 SCREW, SOCKET HD 1/4-20 0.5 LG MHSSH142012 MHSSH142012

89 NUT, HEX 6-32 MHNH632 MHNH632

90 NUT, JAM 1/2-20 MHNHJ1220 MHNHJ1220

91 SCREW, SET 3/8-16 X .500 LG MHSST381612 MHSST381612

92 BUSHING, GUIDE POST MPSB074 MPSB074

93 WASHER, SHIM #6 (.031) MH311150019 MH311150019

94 SPACER, NYLON 0.166 ID X1/4 LG MH110969111 MH110969111

95 PLATE, CONTROLLER MPP90011 MPP90011

96 WIRE, GROUND ASS'Y MPW90125 MPW90125

A1 PLATEN, HEAT ASS'Y MPP2041

A

MPP2042

A

A2 HANDLE, PRESSURE ASS'

Y

MPSH515 MPSH515

A3 CAM ASS'

Y

MPSC213 MPSC213

A

4

BASE ASSEMBL

Y

MPSB204

A

MPSB204

A

A

5

PLATEN, LOWER ASSY MASP00

7

MASP00

7

A

6

PLATEN, HEAT W/WIRNG MPP2041

W

MPP2042

W

®

Service: (800) 426-3609 • Fax: (562) 861-1519 • (562) 861-2566 • Sales: (800) 421-6971 (562) 404-3000 • Fax: (562) 404-3010

http://www.instagraph.com

13925 E. 166th Street • Cerritos CA USA 90702-7900

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